Power tool having a multi-latch battery interface

ABSTRACT

This application relates to a cordless power tool system including a set of cordless power tools, a set of rechargeable and removable battery packs, and a set of battery pack chargers.

RELATED APPLICATIONS

This application claims priority under 35 U.S.C. § 119(e) to U.S.Provisional Patent Application No. 63/063,520, filed Aug. 10, 2020,titled “Power Tool Having a Multi-Latch Battery Interface.”

TECHNICAL FIELD

This application relates to a cordless power tool system including a setof cordless power tools, a set of rechargeable and removable batterypacks, and a set of battery pack chargers.

BACKGROUND

Electric tools include an electric motor and require a source ofelectricity to power the motor. Electric tools may be broken down intotwo groups: (1) corded electric tools that source electricity through acord plugged into a source of alternating current and (2) cordlesselectric tools that source electricity from a battery. Cordless electrictools may be broken down into two groups: (1) tools that use aninternal, integrated battery and (2) tools that use a removable batterypack.

The cordless electric tools that use a removable battery pack and theremovable battery pack that provides electricity (energy/power) to acordless electric tool requires a combination interface between the tooland the pack. The tool includes a tool interface portion/aspect/elementof the combination interface and the pack includes a pack interfaceportion/aspect/element of the combination interface. The combinationinterface allows the tool and the pack to couple/mate anddecouple/unmate with each other such that when the tool and the pack arecoupled/mated the pack will provide power to the tool and will stayaffixed to the tool during operation of the combination.

The combination interface is configured and defined such that only toolsand packs that are intended to work with each will be able to fullycouple/mate. Particularly, different tool and pack manufacturersconfigure and define the combination interface between their tools andpacks such that a tool of one manufacturer will not fully couple/matewith a battery pack of another manufacture. In some configurations, thecombination interface may include one or more guide rails that allowinsertion of the battery pack along a receiving axis (direction) untilelectrical contact is made between a battery pack terminal block holdinga plurality of battery pack terminals and a power tool terminal blockholding a plurality of power tool terminals.

A latching mechanism is typically provided to lock the removable batterypack to the tool. The latching mechanism may include male/femalecomponents provided as part of the battery pack interface, the toolinterface, or a combination of the two. In some configurations, thelatching mechanism is provided in the form of an actuatable stop thatlocks the battery pack relative to the tool along the insertion axis.

A battery pack typically includes a series of battery cells connected ina series, parallel, or series/parallel configuration. The battery cellsmay be electrically connected in series to increase the voltage ratingof the battery pack, in parallel to increase the current and/or chargecapacity of the battery pack, or a combination of series and parallelconfiguration. For example, a battery pack marketed as a 20V Max batterypack in the power tool industry with a nominal voltage of approximately18V may include a single string of five battery cells (5S1P), ormultiple such strings of five battery cells connected in parallel (5SxP,where x>1). The battery pack current capacity, and consequently itsruntime, may be increased by increasing the number of parallel stringsof battery cells. In this example, the parallel connections are made atthe ends of the strings, though it should be understood that parallelconnections may also be made between corresponding nodes of differentstrings of battery cells. In an example embodiment, the battery pack maybe a convertible battery pack where the strings of cells may beswitchably configured in series or parallel depending on the voltagerequirement of the power tool it is intended to supply energy to. U.S.Pat. No. 9,406,915, which is incorporated herein by reference in itsentirety, describes examples of such a convertible battery pack.

A power tool may be configured to receive battery packs of differentvoltage or capacity ratings. For example, a high-power tool such as aconcrete breaker or a rotary hammer may be configured to receive one ormore conventional 60V Max 4 Ah battery packs, or one or more highervoltage (e.g., 120V) battery packs to increase the output speed and/orpower output of the tool, or one or more high capacity (e.g., 6 A.h.)battery packs to increase the battery pack runtime and/or power output.The higher voltage and/or higher capacity battery packs in this examplemay be generally different in size or shape than conventional batterypacks. What is needed is a mechanism that provides effective structuralsupport and ease of operation for battery packs of different sizes orshapes on the power tool.

SUMMARY

According to an example embodiment, a power tool is provided including ahousing; and a battery receptacle formed in the housing or coupled tothe housing, the battery receptacle capable of receiving a first batterypack having a first latching location or a second battery pack having asecond latching location. In an embodiment, the battery receptacleincludes a multi-latch mechanism configured to engage the latchinglocation of first battery pack when receiving the first battery pack andengage the latching location of the second battery pack when receivingthe second battery pack.

In an embodiment, the battery receptacle comprises a power terminalblock and at least one guide rail for guiding the first battery pack orthe second battery pack along a receiving axis so as to make anelectrical connection with the power terminal block.

In an embodiment, the first latching location is closer to the powerterminal block than is the second latching location.

In an embodiment, the multi-latch mechanism includes a first latch hookpivotable around a first pivot member and a second latch hook pivotablearound a second pivot member.

In an embodiment, the first battery pack comprises a pocket at the firstlatching location.

In an embodiment, the second battery pack comprises a translating latchat the second latching location moveable via an actuator in a directionperpendicular to a receiving axis of the second battery pack.

In an embodiment, the first and second battery packs are received alongthe same receiving axes.

According to an embodiment, a power tool is provided including a housingand a battery receptacle formed in the housing or coupled to thehousing. In an embodiment, the battery receptacle includes a multi-latchmechanism comprising a first latch interface for engaging a firstbattery pack when the first battery pack is received in the batteryreceptacle and a second latch interface disposed at a distance from thefirst latch interface for engaging a second battery pack when the secondbattery pack is received in the battery receptacle.

In an embodiment, the first latch interface comprises a first armpivotable around a first pivot member and having a first latch hook forengaging the first battery pack, and the second latch interfacecomprises a second arm pivotable around a second pivot member and havinga second latch hook for engaging the second battery pack.

In an embodiment, the multi-latch mechanism further comprises anactuator configured to move both the first latch interface and thesecond latch interface from a latched position to a released position.

In an embodiment, the second latch interface is integrally formed withthe actuator.

In an embodiment, a first end of the first arm is coupled to the firstpivot member and a second end of the first arm is coupled to theactuator.

In an embodiment, the second end of the first arm is unfixedly coupledto the actuator.

In an embodiment, the first latch interface is coupled to a firstactuator and the second latch interface is coupled to a second actuatorindependent from the first actuator.

In an embodiment, the first latch interface includes a first lateralrecess arranged to engage a first translating latch of the first batterypack and the second latch interface includes a second lateral recessdistanced from the first lateral recess arranged to engage a secondtranslating latch of the second battery pack.

In an embodiment, the first latch interface includes a pivoting arm forpivoting engagement with the first battery pack and the second latchinterface includes a lateral recess for engagement with a translatinglatch of the second battery pack.

In an embodiment, the first latch interface includes a first pivotinglatch hook and the second latch hook includes a second pivoting latchhook. In an embodiment, the multi-latch mechanism further includes asliding actuator configured to move along an axis parallel to areceiving axis of the first and second battery packs.

In an embodiment, the sliding actuator includes a slot that engages thefirst latch interface and an end that engages the second latchinterface.

In an embodiment, the slot is sized to allow relative movement of thesecond latch interface relative to the sliding actuator.

In an embodiment, the first latch interface includes a first pivotinglatch hook and the second latch hook includes a second pivoting latchhook. In an embodiment, the multi-latch mechanism further includes apush actuator configured to move along an axis perpendicular to areceiving axis of the first and second battery packs.

In an embodiment, the sliding actuator includes a slot that engages thefirst latch interface and an end that engages the second latchinterface.

In an embodiment, the slot is sized to allow relative movement of thesecond latch interface relative to the sliding actuator.

In an embodiment, the first latch interface includes a pair of pivotingarms arranged to engage side grooves of the first battery pack.

In an embodiment, the first latch interface includes a pair of slidingside plates arranged to engage side grooves of the first battery pack.

BRIEF DESCRIPTION OF THE DRAWINGS

The drawings described herein are for illustration purposes only and arenot intended to limit the scope of this disclosure in any way.

FIG. 1 illustrates a side, elevation view of an example embodiment of apower tool including a single latching interface.

FIG. 2 illustrates a bottom, plan view of the example power tool of FIG.1.

FIG. 3 illustrates a bottom, isometric view of the power tool of FIG. 1,

FIG. 4 illustrates a rear, elevation view of a first example embodimentof a battery pack.

FIG. 5 illustrates a left side, elevation view of the battery pack ofFIG. 4.

FIG. 6 illustrates a front, elevation view of the battery pack of FIG.4.

FIG. 7 is an isometric view of the battery pack of FIG. 4.

FIG. 8 illustrates a partial isometric view of an example embodiment ofan electric power tool having an example embodiment of a multi-latchmechanism.

FIG. 9 illustrates a partial isometric view of the example electricpower tool with half of a housing removed.

FIG. 10 illustrates an isometric view of an example embodiment of apower tool battery receptacle including the multi-latch mechanism ofFIG. 8.

FIG. 11 illustrates a front, elevation view of the example receptacleand multi-latch mechanism of FIG. 10.

FIG. 12 illustrates a front, isometric view of the example receptacleand multi-latch mechanism of FIG. 10, wherein half of the receptaclehousing is removed.

FIG. 13 illustrates a side, elevation view of the example receptacle andmulti-latch mechanism of FIG. 10, wherein half of the receptacle housingis removed.

FIG. 14 illustrates a rear, isometric view of the example receptacle andmulti-latch mechanism of FIG. 10, wherein half of the receptacle housingis removed.

FIG. 15 illustrates a top, plan view of the multi-latch mechanism ofFIG. 10.

FIG. 16 illustrates a rear, isometric view of the multi-latch mechanismof FIG. 15 in a latching position.

FIG. 17 illustrates a rear, isometric view of the multi-latch mechanismof FIG. 15 in a releasing position.

FIG. 18 illustrates a section view of the multi-latch mechanism of FIG.17.

FIG. 19 illustrates a front, plan view of the multi-latch mechanism ofFIG. 17.

FIG. 20 illustrates a left side, elevation view of the example batterypack of FIG. 4 positioned in the example power tool receptacle of FIG.10, wherein half of the receptacle housing is removed and themulti-latch mechanism is in the releasing position.

FIG. 21 illustrates a front, isometric view of FIG. 20.

FIG. 22 illustrates a left side, elevation view of the example batterypack of FIG. 4 positioned in the example power tool receptacle of FIG.10, wherein half of the receptacle housing is removed and themulti-latch mechanism is in the latching position.

FIG. 23 illustrates a front, isometric view of FIG. 22.

FIG. 24 illustrates a rear, isometric view of an example embodiment of asecond battery pack.

FIG. 25 illustrates a rear, elevation view of the battery pack of FIG.24.

FIG. 26 illustrates a left side, elevation view of the battery pack ofFIG. 24.

FIG. 27 illustrates a top, plan view of the battery pack of FIG. 24.

FIG. 28 illustrates a left side, elevation view of the example batterypack of FIG. 24 positioned in the example power tool receptacle of FIG.10, wherein half of the receptacle housing is removed and themulti-latch mechanism is in the releasing position.

FIG. 29 illustrates a front, isometric view of FIG. 28.

FIG. 30 illustrates a left side, elevation view of the example batterypack of FIG. 24 positioned in the example power tool receptacle of FIG.10, wherein half of the receptacle housing is removed and themulti-latch mechanism is in the latching position.

FIG. 31 illustrates a front, isometric view of FIG. 30.

FIG. 32 illustrates a partial isometric view of another exampleembodiment of a power tool having another example embodiment of amulti-latch mechanism, wherein half of the tool housing is removed.

FIGS. 33-38 illustrate the example power tool of FIG. 32 and an exampleembodiment of a third battery pack.

FIGS. 39-45 illustrate the example power tool of FIG. 32 and an exampleembodiment of a fourth battery pack.

FIGS. 46-53 illustrate the example power tool of FIG. 32 with analternative example embodiment of the multi-latch mechanism and analternative example embodiment of the third battery pack.

FIGS. 54-58 illustrate the example power tool of FIGS. 46-53 and analternative example embodiment of the fourth battery pack.

FIG. 59 illustrates a partial left side, elevation view of anotherexample embodiment of a power tool having another example embodiment ofa multi-latch mechanism, wherein half of the tool housing is removed.

FIGS. 60-63 illustrate the example power tool of FIG. 32 with analternative example embodiment of the multi-latch mechanism and analternative example embodiment of the third battery pack.

FIGS. 64-67 illustrate the example power tool of FIGS. 59-63 and analternative example embodiment of the fourth battery pack.

FIG. 68 illustrates a partial left side, elevation view of anotherexample embodiment of a power tool having another example embodiment ofa multi-latch mechanism, wherein half of the tool housing is removed.

FIGS. 69-76 illustrate the example power tool of FIG. 68 and the exampleembodiment of the third battery pack of FIGS. 60-63.

FIGS. 77-84 illustrate the example power tool of FIG. 68 and the exampleembodiment of the fourth battery pack of FIGS. 64-67.

FIGS. 85 and 86 illustrate a partial left side, elevation view and apartial rear, isometric view, respectively, of an alternative exampleembodiment of the power tool and an alternative example embodiment ofthe multi-latch mechanism of FIG. 68, wherein half of the tool housingis removed.

FIGS. 87-91 illustrate the example power tool of FIGS. 85 and 86 and analternative example embodiment of the third battery pack.

FIGS. 92-96 illustrate the example power tool of FIGS. 85 and 86 and analternative example embodiment of the fourth battery pack.

FIGS. 97-99 illustrate a partial, front elevation view, a partial, frontelevation view wherein half of the tool housing is removed, and partialleft side elevation view wherein half of the tool housing is removed,respectively of an alternative example embodiment of a power tool havingan alternative example embodiment of a multi-latch mechanism.

FIGS. 100-105 illustrate the example power tool of FIGS. 97-99 and anexample embodiment of the third battery pack of FIGS. 33-38.

FIGS. 106-111 illustrate the example power tool of FIGS. 97-99 and analternative example embodiment of the fourth battery pack.

FIGS. 112-116 illustrate another example embodiment of a power toolhaving another example embodiment of a multi-latch mechanism, whereinhalf of the tool housing is removed and example embodiment of the thirdbattery pack of FIGS. 33-38.

FIGS. 117-120 illustrate the example power tool of FIGS. 112-116 and theexample embodiment of the fourth battery pack of FIGS. 77-84.

FIG. 121 illustrates a partial, left side elevation of another exampleembodiment of a power tool having another example embodiment of amulti-latch mechanism.

FIGS. 122-126 illustrate the example power tool of FIG. 121 and theexample embodiment of the third battery pack of FIGS. 69-76.

FIGS. 127-130 illustrate the example power tool of FIG. 121 and theexample embodiment of the fourth battery pack of FIGS. 77-84.

FIGS. 131-134 illustrate another example embodiment of a power toolhaving another example embodiment of a multi-latch mechanism.

FIGS. 135-138 illustrate the example power tool of FIGS. 131-134 and theexample embodiment of the third battery pack of FIGS. 69-76.

FIGS. 139-142 illustrate the example power tool of FIGS. 131-134 and theexample embodiment of the third battery pack of FIGS. 77-84.

FIGS. 143-149 illustrate another example embodiment of a power toolhaving another example embodiment of a multi-latch mechanism and anotheralternative example embodiment of the third battery pack.

FIG. 150 illustrates the example embodiment of the power tool of FIGS.143-149 and another alternative example embodiment of the fourth batterypack.

FIGS. 151-155 illustrate another example embodiment of a power toolhaving another example embodiment of a multi-latch mechanism.

FIGS. 156 and 157 illustrate rear, elevation views of the multi-latchmechanism, in a latching position and a releasing position,respectively.

FIGS. 158-160 illustrate the example power tool of FIGS. 151-155 andanother example embodiment of the third battery pack.

FIGS. 161-163 [[164]] illustrate the example power tool of FIGS. 151-155and another example embodiment of the fourth battery pack.

DETAILED DESCRIPTION

The following description illustrates the claimed invention by way ofexample and not by way of limitation. The description clearly enablesone skilled in the art to make and use the disclosure, describes severalembodiments, adaptations, variations, alternatives, and uses of thedisclosure, including what is presently believed to be the best mode ofcarrying out the claimed invention. Additionally, it is to be understoodthat the disclosure is not limited in its application to the details ofconstruction and the arrangements of components set forth in thefollowing description or illustrated in the drawings. The disclosure iscapable of other embodiments and of being practiced or being carried outin various ways. Also, it is to be understood that the phraseology andterminology used herein is for the purpose of description and should notbe regarded as limiting.

Embodiments of the invention described herein are discussed withreference to a long battery pack and a short battery pack by way ofexample to illustrate two different types of battery packs havingdifferent latching locations. It should be understood, however, thatsize of the battery pack is not the only determining factor, and that insome configurations, battery packs with substantially the same size maybe designed to include different latching locations. For the purpose ofthis disclosure, a “long battery pack” designates a battery pack havinga latching location (or catching location, as the case may be) at afirst distance from a battery vertical datum plane (or vertical datumplane) and a “short battery pack” designates a battery pack having alatching location (or a catching location, as the case may be) at asecond distance from the battery vertical datum plane, wherein the firstdistance is greater than the second distance. The vertical datum planeis generally perpendicular to the receiving axis. The vertical datumplane serves to define relative positions and orientations of variouselements of the battery pack and the combination interface.

FIGS. 1-3 illustrate an example embodiment of a first electric powertool 10. The power tool 10 includes a tool housing 12. The tool housing12 includes left side portion 12 a and a right side portion 12 b. Theleft side portion 12 a and the right side portion 12 b combine toprovide the tool housing 12 and form a battery pack receptacle 14. Thepower tool housing 12 also includes a handle 16 for holding the powertool 10 and trigger 18. The power tool 10 also includes an electricmotor (not shown) coupled to a tool terminal block 20. The tool terminalblock 20 holds a set of tool terminals 22. The tool terminals 22 areconfigured to mate with a corresponding set of battery pack terminals,described in more detail below. The trigger 18 allows a user to supplypower from an attached battery pack to the motor.

The battery pack receptacle 14 includes a tool interface portion 24(sometimes referred to as a battery pack interface) of a combinationinterface between the power tool and the battery pack. The toolinterface 24 may also include a set of rails 26 and a corresponding setof grooves 28 formed by the rails 26. The tool interface may alsoinclude a catch 30 for receiving a corresponding latch of a batterypack, described in more detail below. The tool 10 includes a toolvertical datum plane 32 that serves a basis to define relative positionsand orientations of various elements of the power tool 10, in general,and of the combination interface, relative to a vertical plane.

In the example embodiment, a battery pack couples to and uncouples fromthe power tool 10 along the X axis. In the example embodiment, the catch30 includes a catch wall 34 that is generally perpendicular to the toolvertical datum plane 32. The catch wall 34 is configures to abut abattery pack latch, particularly a latch face or latch wall, when thebattery pack is fully coupled to the power tool 10. In the exampleembodiment, there is a distance “m” between the vertical datum plane 32and the catch wall 34. The distance “m” extends along the X axis.

FIGS. 4-7 illustrate an example embodiment of a first battery pack 50 a.For purposes of this disclosure, the battery pack 50 a is designated asa “short” battery pack, as will be explained below. The battery pack 50a includes a main housing 52 that houses a plurality of battery cells(not shown), and one or more guide rails 54 that form elongate grooves56 along the sides. The battery pack also includes a set of slots 58formed in a battery vertical datum plane 60. The battery vertical datumplane 60 serves a basis to define relative positions and orientations ofvarious elements of the battery pack 50, in general, and of thecombination interface, relative to a vertical plane. The plurality ofslots provide access to a plurality of battery pack terminals (notshown). The battery pack terminals are housed in a battery pack terminalblock (not shown). As the battery pack 50 a is slid into the batteryreceptacle 14 along the receiving axis X, the guide rails 24 arereceived within the elongate grooves 58 of the battery pack 50 a, andthe battery pack 50 a is guided along the receiving axis X until thebattery pack terminals mate with the power tool terminals 22 of thebattery receptacle 14.

The battery pack 50 further includes a male moving hook member (hereinalso referred to as a translating latch or simply a latch) 62 disposedon top of battery pack housing 52 between the guide rails 56. Thetranslating latch 62 is spring-loaded and is coupled to an actuator 64disposed on the battery pack housing 52. The latch 62 includes a latchface or wall 64 that is generally perpendicular to the battery verticaldatum plane 60. The actuator 64, when pressed, causes translating latch62 to move downwardly in a direction generally perpendicular to thereceiving axis X.

In the example embodiment, there is a distance “m” between the batteryvertical datum plane 60 and the catch wall 34. The distance “m” extendsalong the X axis.

The battery pack 50 is adapted to mate with the power tool 10. As notedabove, the power tool 10 includes a female catch member (e.g., a pocketor recess) 30 located to engage the male hook member (e.g., translatinglatch 62) to hold the battery pack 50 in place within a batteryreceptacle of the power tool. The catch member of the power tool must bepositioned at a specific location designed to correspond to the locationof the translating latch 60 of the battery pack 50. This location is ata distance “m” from the tool vertical datum plane. Engagement of thetranslating latch 62 with the catch member of the power tool axiallyblocks and locks the battery pack 50 into the battery receptacle of thepower tool. It is noted that while in this example the battery pack 50is provided with a male hook member, it may be alternatively providedwith a female catch (e.g., a pocket or a recess) that engages a malehook member (e.g., an actuatable translating hook) provided on thebattery receptacle of the power tool. The male hook member on either thebattery pack or the battery receptacle may be a moveable component or astationary component. Similarly, the female catch member on either thebattery pack or the battery receptacle may be a movable component or astationary component. For example, the female catch may be provided as amoveable pocket within the battery receptacle that interfaces with afixed male hook on the battery pack. Alternatively, both the batteryreceptacle and the battery pack may include moveable components thatcooperate together to latch and/or release the battery pack.

FIG. 8 illustrates a partial isometric view of an example embodiment ofan electric power tool 90 having a first example embodiment of amulti-latch mechanism 100. FIG. 9 illustrates a partial isometric viewof the electric power tool 90 with half of the tool housing removed.

The power tool 90 includes a housing 92 that houses an electric motor(not shown) therein. The electric motor imparts a rotary movement on oneor more transmission components (not shown) for producing a rotaryand/or reciprocating motion on an output spindle. The electric motor maybe, for example, a brushless direct-current (BLDC) motor and may beconfigured to output a maximum power output of at least 1500 watts. Theelectric motor is powered by a secondary battery pack (not shown) thatis removably mounted on a battery receptacle 94 of the housing 92. Thebattery receptacle 94 includes a tool terminal block (not shown) housinga plurality of tool terminals that mate with corresponding terminals ofthe battery pack to supply DC power to the electric motor. A triggerswitch 96 may be provided on a handle 98 for selectively activatingsupply of power from the battery pack to the electric motor. While thepower tool 90 in this example is a motorized hammer, it should beunderstood that any rotary or non-rotary cordless power tool thatincludes a motor, including but not limited to, hammer drills,demolition hammers, grinders, sanders, drills, impact drivers, cut-outtools, polishers, saws, circular saws, miter saws, reciprocating saws,nailers, etc., or any other powered apparatuses that receive power toolbattery packs, including but not limited to lighting devices, radios,mowers, trimmers, blowers, etc., is encompassed by the term “power tool”as used within this disclosure. The power tool 90 is powered by one ormore battery packs that provide a total rate voltage in the range of 60V to 120 V to the power tool. A battery pack having a rated voltage of60 V has a maximum voltage of approximately 63 V, a minimum workingvoltage of approximately 30 V prior to shutoff, and a nominal (average)voltage of approximately 54 V.

FIGS. 10-14 illustrate an example embodiment of a power tool batterypack receptacle 114 including the multi-latch mechanism 100 illustratedin FIGS. 8 and 9. The battery pack receptacle 114 is optionally providedwith a cavity 122 that houses the battery pack 50. The cavity 122 may besuitable for use in power tool applications involving large amount ofdebris and contamination. Though the cavity 122 is displayed in variousembodiments of this disclosure, it should be understood that the cavity122 is provided merely by way of example and is not an essential part ofthe disclosure.

The power tool 90 may be configured to receive battery packs 50 ofdifferent voltage or capacity ratings. For example, the power tool 90may be configured to receive one or more conventional 60V Max 4 Ahbattery packs, or one or more higher voltage (e.g., 120V) battery packsto increase the output speed and/or power of tool, or one or more highcapacity (e.g., 6 Ah) battery packs to increase the battery pack runtimeand/or power output.

Increasing the number of cells in a battery pack may result in anincrease in the length (i.e., along the insertion axis A) of the batterypack. In many configurations, it is preferable for the latching locationbe positioned in proximity to the rear of the battery pack or close tothe center in order to limit wobble and vibration of the pack. Inaddition, where a translating latch and an actuator is utilized asdescribed above, mechanically linking the movement from the actuator tothe latch can be complex and difficult in a long battery pack unless thelatch is positioned in relative proximity of the actuator. Furthermore,in some configurations, the area adjacent to the battery pack terminalblock may be used for other purposes, for example to house a circuitboard, making it difficult to position the latching location uniformlyacross different battery pack platforms.

To enable the power tool 90 to engage and lock in different batterypacks 50 of different sizes, voltage ratings, capacity ratings, orconfigurations provided with different latching locations, the batteryreceptacle 114 is provided with multi-latch mechanism 100, as describedin detail herein. In an embodiment, the multi-latch mechanism 100 isdisposed on the battery receptacle 114 to engage and lock at least twodifferent battery packs 50 having different latching configurations.

FIGS. 15-19 illustrate various views of the multi-latch mechanism alone100 in latching and releasing positions. The multi-latch mechanism 100includes a first interface element 110 for engagement with short batterypack 50 a, a second interface element 120 for engagement with longbattery pack 50 b, and an actuator 130 engageable outside batteryreceptacle 114 by a user to move both of the interfaces 120 and 130 ofthe multi-latch mechanism 100 from the latching position to thereleasing position simultaneously.

The first interface element 110 includes an arm 112 pivotably coupled tobattery receptacle 114 via a first pivot member 114. The first interfaceelement 110 further includes a first latch member 116 projectingdownwardly from approximately a middle portion of the arm 112. In anembodiment, the first latch member 116 includes a downward straightsurface 116 a and a ramped surface 116 b. The ramped surface 116 ballows sliding movement of the battery pack into the battery receptacle114. The downward straight surface 116 a forms a hook for engagementwith a corresponding female catch member (e.g., a pocket or a recess) ofthe battery pack in the latched position, as described in more detailbelow. Alternatively, the downward straight surface 116 a forms a catchfor engagement with a corresponding male hook member (e.g., atranslating latch) of the battery pack in the latched position, asdescribed in more detail below.

The actuator 130 includes an arm 132 that is coupled on a first end to afront end 118 of arm 112 of first interface element 110 and includes anengagement portion 136 on a second end. A middle portion of arm 132 iscoupled to the battery receptacle 114 via a second pivot member 134.Downward actuation of the engagement portion 136 causes the first end ofarm 112 to move upwardly around the second pivot member 134 and causeupward movement of the first interface element 110 away from the batterypack.

The second interface element 120 includes a main body 122 coupledbetween the first end of arm 132 of the actuator 130 and the secondpivot member 134, and a second latch member 126 projecting downwardlyfrom the main body 122. In an embodiment, the second latch member 126includes a downward straight surface 126 a and a ramped surface 126 b.The ramped surface 126 b allows sliding movement of the battery packinto the battery receptacle 114. The downward straight surface 126 aforms a hook for engagement with a corresponding female catch member(e.g., a pocket or a recess) of the battery pack in the latchedposition, as described in more detail below. Alternatively, the downwardstraight surface 126 a forms a catch for engagement with a correspondingmale hook member (e.g., a translating latch) of the battery pack in thelatched position, as described in more detail below.

One or more spring elements 128 are mounted on the main body 122 of thesecond interface element 120 to bias the main body 122 downward (in thecontext of FIG. 16), and thus the first latch member 116 and the secondlatch member 126 and the multi-latch mechanism 100 assembly as a whole,into the latching position. The spring elements 128 may be supported viaupright posts provided on the main body 122 of the second interfaceelement 120 on one end and via a housing part 129 on the other end.Alternatively, the spring elements 128 may engage the first interfaceelement 110 or the actuator 130.

Referring to FIGS. 20-23, when the multi-latch mechanism 100 interfaceswith the short battery pack 50 a, the first interface element 110engages the translating latch 62 of the battery pack 50 a in thelatching position. The translating latch 62 is positioned at a distance“m” from the battery vertical datum plane, where m<n (FIGS. 26, 27, 28,30). The first latch member 116 of the first interface element 110 ispositioned to engage and catch a front portion of the translating latch62 when the battery pack 50 a is fully inserted into the batteryreceptacle 114 to lock the battery pack 50 a in place. The first latchmember 116 may be disengaged from the translating latch 62 by pressingthe actuator 130 of the multi-latch mechanism 100 in a direction W.Alternatively, the user may reach into the battery receptacle 114 andpress the actuator 64 of the battery pack 50 a in the direction W todisengage the translating latch 62 from the first interface element 110.The second latch member 126 does not contact the battery pack 50 a whenit is fully inserted into the battery receptacle 114.

FIGS. 23-26 illustrate another example embodiment of a second batterypack 50 b. For purposes of this disclosure, the battery pack 50 b isdesignated as a “long” battery pack, as will be explained below. Thebattery pack 50 b includes a main housing 52 b that houses a pluralityof battery cells (not shown), and one or more guide rails 54 b that formelongate grooves 56 b along the sides. The battery pack 50 b alsoincludes a set of slots 58 b formed in a battery vertical datum plane 60b. The battery vertical datum plane 60 b serves a basis to definerelative positions and orientations of various elements of the batterypack 50 b, in general, and of the combination interface, relative to avertical plane. The plurality of slots 58 b provide access to aplurality of battery pack terminals (not shown). The battery packterminals are housed in a battery pack terminal block (not shown). Asthe battery pack 50 b is slid into the battery receptacle 114 along thereceiving axis X, the guide rails 124 are received within the elongategrooves 58 b of the battery pack 50 b, and the battery pack 50 b isguided along the receiving axis X until the battery pack terminals matewith the power tool terminals 122 of the battery receptacle 114.

The battery pack 50 b further includes a female catch or pocket 62 bdisposed on top of battery pack housing 52 b between the guide rails 56b. The catch 62 b is configured to receive a corresponding latch 126 ofthe multi-latch mechanism 100. The catch 62 b includes a catch face orwall 64 b that is generally perpendicular to the battery vertical datumplane 60 b.

In the example embodiment, there is a distance “n” between the batteryvertical datum plane 60 b and the catch wall 64 b. The distance “n”extends along the X axis.

The battery pack 50 b is adapted to mate with the battery packreceptacle 114. As noted above, the multi-latch mechanism 100 of thebattery pack receptacle 114 includes a male latch member 126 located toengage the female catch k member (e.g., catch 62 b) to hold the batterypack 50 b in place within a battery receptacle 114 of the power tool.The latch member of the power tool must be positioned at a specificlocation designed to correspond to the location of the catch 62 b of thebattery pack 50 a. This location is at a distance “n” from the toolvertical datum plane 60 b. Engagement of the latch member 126 of thepower tool with the catch member 62 b of the battery pack 50 b axiallyblocks and locks the battery pack 50 b into the battery receptacle 114of the power tool. It is noted that while in this example the batterypack 50 b is provided with a female catch member (e.g., a pocket or arecess), it may be alternatively provided with a male hook member (e.g.,an actuatable translating hook) that engages a female catch memberprovided on the battery receptacle of the power tool. The male hookmember on either the battery pack or the battery receptacle may be amoveable component or a stationary component. Similarly, the femalecatch member on either the battery pack or the battery receptacle may bea movable component or a stationary component. For example, the femalecatch may be provided as a moveable pocket within the battery receptaclethat interfaces with a fixed male hook on the battery pack.Alternatively, both the battery receptacle and the battery pack mayinclude moveable components that cooperate together to latch and/orrelease the battery pack.

FIGS. 28-31 illustrate various views of the battery receptacle 114including the multi-latch mechanism 100 interfacing with a long batterypack 50 b in latching and releasing positions. The long battery pack 50ba is provided with a pocket 64 for engagement with the second interfaceelement 120 and the short battery pack 50 a is provided with atranslating latch 62 for engagement with the first interface element110. It should be understood, however, that this arrangement is providedby way of example only and either battery pack may be provided witheither a pocket or a translating latch.

Referring to FIGS. 28-31, when the multi-latch mechanism 100 interfacesthe long battery pack 50 b, the second interface element 120 engages thepocket 64 of the battery pack 50 b in the latched position. The pocket64 is positioned at a distance n relative to the battery vertical datumplane 60 b. The second latch member 126 of the second interface element120 is positioned to engage and catch the pocket 64 when the batterypack 50 b is fully inserted into the battery receptacle 114 to lock thebattery pack 50 b in place. The first latch member 116 may come intocontact with an upper portion of the battery pack 50 b when the actuator130 is disengaged, but it does not engage any pocket or hook of thebattery pack 50 b when it is fully inserted into the battery receptacle114. The second latch member 126 may be disengaged from the pocket 64 ofthe battery pack 50 b by pressing the actuator 130 in the direction W.

FIG. 32 illustrates a partial isometric view of another exampleembodiment of a power tool 90 including another example embodiment of abattery pack receptacle 114 with half the housing removed showinganother example embodiment of a multi-latch mechanism 100′. Themulti-latch mechanism 100′ includes a second interface element 120formed integrally with the actuator 130. As shown here, the secondinterface element 120 extends from a portion of the actuator 130—in thisexample from the second pivot member 134—at a fixed angle relative tothe arm 132 of the actuator 130. Pivoting movement of the engagementportion 136 around the second pivot member 134 thus causes the secondinterface element 120 to pivot away from the battery pack 50. A distalconnection point 138 of the arm 132 of the actuator 130 distalconnection point 138 is coupled to the first interface element 110 andcauses the first interface element 110 to pivot around the first pivotmember 114 away from the battery pack 50. An advantage of thisembodiment is that it reduces the number of components needed formanufacturing of the multi-latch 100′ assembly, thus providing an easierand less expensive manufacturing process.

FIGS. 33-38 illustrate various isometric views of the example embodimentof the battery receptacle 114 with half of the housing removed, showingthe multi-latch mechanism 100′ interfacing with an example embodiment ofa third battery pack 50 c. In this embodiment, the battery pack 50 c isa short battery pack.

FIGS. 39-45 illustrate various isometric views of the battery packreceptacle 114 with half of the housing removing, showing themulti-latch mechanism 100′ interfacing with an example embodiment of afourth battery pack 50 d. In this embodiment, the battery pack 50 d is along battery pack. The battery pack 50 d is similar to the long batterypack 50 b previously described, but it includes a translating latch 70in place of a pocket. The translating latch 70 is spring-loaded and iscoupled to an actuator 72 disposed on the battery pack 50 d. Theactuator 72, when pressed, causes the translating latch 70 to movedownwardly in a direction perpendicular to the receiving axis of thebattery pack 50 d. In an embodiment, the multi-latch mechanism 100according to this embodiment is designed such that, even in the latchedposition, the first and second latch members 116 and 126 are located ator slightly above a top plane of the battery pack 50 d (i.e., the planeat the surface of the battery pack 50 d where the pocket that receivesthe latch 70 opens). Thus, in the latched position, the first and secondlatch members 116 and 126 can catch the translating latch 62 of batterypack 50 c and the translating latch 70 of the battery pack 50 drespectively. However, in this embodiment, the first and second latchmembers 116 and 126 are not capable of extending into a female recess orpocket of the battery pack. Alternatively, however, the multi-latchmechanism 100 may be configured such that the first and second latchmembers 116 and 126 extend below the top plate of the battery pack andare shaped to engage female recesses or pockets as well as maletranslating latches and hooks of various battery packs.

FIGS. 46-57 illustrate various views of another example embodiment of amulti-latch mechanism 100 including an improved second interface element120 configuration. Specifically, the figures illustrate the multi-latchmechanism 100 with the improved second interface element 120 interfacingwith the short battery pack 50 c in latched and released positionsrespectively. The figures illustrate the short battery pack 50 c beinginserted into the battery receptacle 114. The figures also illustratethe multi-latch mechanism 100 with the improved second interface element120 interfacing the long battery pack 50 d in released position (withbattery pack 50 d in motion) and latched position respectively.

In this example embodiment, as shown in the figures, the second latchmember 126 of the second interface element 120 is shaped to allowpassage of the translating latch 62 of the short battery pack 50 cwithout having to be pivoted away from the battery pack 50 c. In oneembodiment, the second latch member 126 is fork-shaped including two ormore spaced-apart teeth forming gaps therebetween. The translating latch62 of the short battery pack 50 c is similarly fork-shaped withcorresponding teeth arranged to slide within the gaps formed between theteeth of the second latch member 126 as the battery pack 50 c isinserted into or removed from the battery receptacle 114. Accordingly,in an embodiment, battery pack 50 c may be removed from or inserted intothe battery receptacle 114 by the user pressing down on actuator 64 ofthe battery pack 50 c, without any actuation of actuator 130 of themulti-latch mechanism 100. As illustrated in the figures, when receivingthe long battery pack 50 d, teeth of the second latch member 126 engagepocket 64 in the latched position a described above. In an embodiment,second latch member 126 includes two outer teeth and a middle tooththerebetween, and the translating latch 62 includes two teeth positionedto slide within the gap formed between the outer and middle teeth of thesecond latch member 126.

In an alternative embodiment, second latch member 126 may be U-shapedwith two outer teeth forming a large enough gap therebetween to allowpassage of the translating latch 62 of the short battery pack 50 cwithout providing teeth on the translating latch 62 or otherwisemodifying the shape of the translating latch 60. In this configuration,in an embodiment, a length of the pocket 64 of the long battery pack 50d is greater than a length of translating latch 60 of the short batterypack 50 c to accommodate the outer teeth of the second latch member 126.The outer teeth of the second latch member 126 are sized to bepositioned around the two sides of the translating latch 60 of the shortbattery pack 50 c as the short battery pack 50 c is inserted into orremoved from the battery receptacle 114.

In yet another embodiment, battery receptacle 114 may include a rib or aramp that gradually presses down on the translating latch 60 as batterypack 50 b is being removed, allowing it to slide past the second latchmember 126.

FIGS. 60-63 illustrate the battery pack 50 c is similar to the shortbattery pack 50 a previously described, but it includes a pocket 74 inplace of a translating latch. In an embodiment, the multi-latchmechanism 100 according to this embodiment is designed such that, in thelatched position, the first and second latch members 116 and 126 arelocated below the top plane of the battery pack 50 c (i.e., the plane atthe surface of the battery pack 50 c where the pocket 74 opens). Thus,in the latched position, the first and second latch members 116 and 126can catch the pocket 74 of battery pack 50 c and the pocket 64 of thebattery pack 50 d respectively. The first and second latch members 116and 126 of this embodiment may be also be utilized to catch translatinglatches of battery packs 50 a and 50 d.

FIGS. 60-63 illustrate various isometric views of alternative exampleembodiment of multi-latch mechanism 100 in which first interface element110 is unfixed to the actuator 130, according to an embodiment. In thisembodiment, distal connection point 138 of the actuator 130 is in not infixed contact with the front end 118 of the first interface element 110.Rather, in an embodiment, distal connection point 138 of the actuator130 detachable from the front end 118 of the first interface element 110in some positions. In an embodiment, distal connection point 138 of theactuator 130 is received through a lower opening 119 formed in the frontend 118 of the first interface element 110 when it contacts the firstinterface element 110.

As shown in FIGS. 60-63, when receiving the short battery pack 50 c, thedistal connection point 138 of the actuator 130 is in contact with thefront end 118 of the first interface element 110 in latched and releasedpositions. When receiving the long battery pack 50 d, the distalconnection point 138 of the actuator 130 is in out of contact with thefront end 118 of the first interface element 110 in the latched positionas the first latch member 116 rests on top of the battery pack 50 d. Inthe release position, the distal connection point 138 of the actuator130 is received within the lower opening 119 of the front end 118 of thefirst interface element 110 to engage and lift the first latch member116 away from the battery pack 50 d.

FIGS. 68-82 illustrate various views of another example embodiment of apower tool battery receptacle 114 provided with another exampleembodiment of a multi-latch mechanism 200 having at least twoindependently actuated interfaces. The battery receptacle 114 and themulti-latch mechanism 200 interface with the long battery pack 50 d inlatched and released positions respectively. The battery receptacle 114and the multi-latch mechanism 200 interface with the short battery pack50 c in latched and released positions respectively.

As shown in these figures, the multi-latch mechanism 200 includes afirst interface element 210 for engagement with the pocket 74 of theshort battery pack 50 c and a second interface element 220 forengagement with the pocket 64 of the long battery pack 50 d.

In an embodiment, the first interface element 210 includes a first arm212 pivotably coupled to a first actuator 218 via a first pivot member214 supported by the battery receptacle 114. First interface 210 furtherincludes a first latch member 216 projecting downwardly fromapproximately an end of the first arm 212. Similarly, the secondinterface element 220 includes a second arm 222 pivotably coupled to asecond actuator 228 via a second pivot member 224 supported by thebattery receptacle 114. The second interface element 220 furtherincludes a second latch member 226 projecting downwardly fromapproximately an end of the second arm 222.

The battery receptacle 114 in this embodiment includes first and secondrecesses or openings 230 and 232 through which the first and secondactuators 218 and 228 are accessible and engageable by the user. In anembodiment, the second recess 232 is provided at an end of the batteryreceptacle 114 away from the housing 12 (i.e., the handle portion inthis example), and the first recess 230 is provided between the housing12 and the second recess 232. In an embodiment, the first and secondpivot members 224 are provided below the recesses 230 and 232.

Each of the first and second actuators 218 and 228 is spring-loaded(e.g., via a spring that is not shown) to a latched position andoperates independently by the user to move the first and secondinterfaces 210 and 220 from the latched position to the releasedposition. Thus, in an embodiment, to remove the short battery pack 50 cfrom the battery receptacle 114, the user initially presses the firstactuator 218 to disengage the battery pack 50 c, and then presses thesecond actuator 228 to allow passage of the battery pack 50 c out of thebattery receptacle 114.

Alternatively, the second latch member 216 has a greater width and/orshape than the first latch member 226. The pocket 64 of the long batterypack 50 d similarly has a greater corresponding width and/or shape thanthe pocket 74 of the short battery pack 50 c. The second latch member216 therefore does not slide into the pocket 74 as the short batterypack 50 c is being inserted or removed from the battery receptacle 114.

The above description of the second embodiment is made by way of examplewith reference to battery packs 50 c and 50 d having pockets 74 and 64respectively. In an alternative embodiment, as shown in FIGS. 85-96, themulti-latch mechanism 200 may be additionally and/or alternativelyconfigured to interface with battery packs 50 c and 50 d havingtranslating latches 60 and 70 respectively. The multi-latch mechanism200 according to this embodiment is designed such that, even in thelatched position, the first and second latch members 216 and 226 arelocated at or slightly above a top plane of the battery packs 50 c and50 d (i.e., the plane at the surface of the battery pack where thepocket 74 or 64 opens). Thus, in the latched position, the first andsecond latch members 216 and 226 can catch the translating latch 62 ofbattery pack 50 c and the translating latch 70 of the battery pack 50 drespectively. However, in this embodiment, the first and second latchmembers 216 and 226 are not capable of extending into a female recess orpocket of the battery pack. Alternatively, however, multi-latchmechanism 200 may be configured such that the first and second latchmembers 216 and 226 extend below the top plate of the battery pack andshaped to engage female recesses or pockets as well as male translatinglatches and hooks of various battery packs.

According to an embodiment, first arm 212 of first interface element 210may be additionally provided with side walls 213 extending from twosides of the first latch member 216 to delimit lateral movement of thetranslating latch 62 when receiving the short battery pack 50 c.Similarly, second arm 222 of second interface element 220 may beadditionally provided with side walls 223 extending from two sides ofthe second latch member 226 to delimit lateral movement of thetranslating latch 70 when receiving the long battery pack 50 d.

FIGS. 97-111 illustrate various views of another example embodiment of apower tool battery receptacle 114 provided with another exampleembodiment of a multi-latch mechanism 300 having at least two discreteand spaced-apart stationary female catches in the form of fixed pocketsfor engagement with moveable male hooks in the form of translatinglatches of different battery packs, according to a third embodiment ofthe invention. As shown in these figures, in an embodiment, multi-latchmechanism 300 includes a first pocket 310 for engagement with shortbattery pack 50 c having translating latch 62 and a second pocket 320for engagement with long battery pack 50 d having translating latch 70at a different location from translating latch 62. The first and secondpockets 310 and 320 are formed as lateral recesses formed in a lowersurface of the battery receptacle 114 facing the top of the batterypack. Each pocket 310 and 320 includes a straight front surface arrangedperpendicularly to the receiving axis of the battery pack, and a slopedrear surface extending downwardly from the top of the straight surface.The first pocket 310 is disposed closer to the housing 90 (in this casethe power tool handle) than is second pocket 320. The second pocket 320is disposed close to a front end of the battery receptacle 114 and firstpocket 310 is disposed approximately halfway between the handle and thesecond pocket 320. In an embodiment, a distance between the first andsecond pockets is in the range of 1-5 cm, preferably approximately 2-4cm.

FIGS. 112-120 illustrate various views of another example embodiment ofa power tool battery receptacle 114 provided with another exampleembodiment of a multi-latch mechanism 400 having a stationary femalecatch in the form of a fixed pocket 410 provided for engagement with amoveable male hook in the form of a translating latch of a battery pack,provided at a distance from moveable male hook in the form of anactuatable interface 420 for engagement with a stationary female catchin the form of a pocket of a different battery pack, according to afourth embodiment of the invention. As shown in these figures, in anembodiment, the pocket 410 is positioned to engage with the translatinglatch 62 of the short battery pack 50 c, and actuatable interface 420 ispositioned to engage the pocket 64 of the long battery pack 50 d. In anembodiment, actuatable interface 410 is similar to second interfaceelement 220 of the second embodiment described above, and includes anarm 422 pivotably coupled to an actuator 428 via a pivot member 414supported by the battery receptacle 114 and a latch member 426projecting downwardly from approximately an end of the arm 422. In anembodiment, pocket 410 is similar to pocket 310 of the third embodimentdescribed above and includes a vertical surface and an angled surfaceformed in the lower surface of the battery receptacle 114. In anembodiment, pocket 410 is disposed closer to the housing 90 (in thiscase the power tool handle) than is actuatable interface 420.

FIGS. 121-130 illustrate various views of another example embodiment ofa power tool battery receptacle 114 provided with another exampleembodiment of a multi-latch mechanism 500 having two interfaces actuatedby a horizontally sliding actuator 530, according to a fifth embodimentof the invention. The figures illustrate views of the multi-latchmechanism 500 including the horizontally sliding actuator 530.

As shown in these figures, in an embodiment, the multi-latch mechanism500 includes a first interface element 510 for engagement with the shortbattery pack 50 c and a second interface element 520 for engagement withthe long battery pack 50 d.

The first interface element 510 includes a first arm 512 pivotablycoupled to a first actuator 518 via a first pivot member 514 supportedby the battery receptacle 114. The first interface element 510 furtherincludes a first latch member 516 projecting downwardly fromapproximately an end of the first arm 512. Similarly, the secondinterface element 520 includes a second arm 522 pivotably coupled to asecond actuator 528 via a second pivot member 524 supported by thebattery receptacle 114. The second interface element 520 furtherincludes a second latch member 526 projecting downwardly fromapproximately an end of the second arm 522. In an embodiment, both firstand second actuators 518 and 528 extend approximately vertically.

The sliding actuator 530 includes a main planar body 534 and a sliderbutton 532 projecting vertically upwardly from the main body 534. Thebattery receptacle 114 includes an opening 540 through which the sliderbutton 532 is accessible and slidable between two positions. The opening540, in an embodiment, is formed on top of the battery receptacle 114and includes a width slightly greater than a length of the slider button532 and a length that allows traversal movement of the slider button 532between the two positions. The main body 534 of the sliding actuator 530is located below the opening 540 of the battery receptacle 114.

The sliding actuator 530 further includes a slot 536 forward of theslider button 532 and a rear end 538 rearward of the slider button 532.The slot 536 is sized and positioned to receive the first actuator 518of the first interface element 510 therein. The rear end 538 is arrangedto be mechanically coupled to the second actuator 528 of the secondinterface element 520. The first actuator 518 is sized such that a topportion of the first actuator 518 is received within the slot 536 butdoes not protrude out of the top of the slot 536 to avoid contact withthe battery receptacle 114. Similarly, a top portion of the secondactuator 528 is connected (e.g., via a known means such as a pin andsocket or a snap) to the rear end 538 so as to avoid contact with thebattery receptacle 114.

As shown in the figures sliding movement of the slider button 532 in arear direction ‘E’ moves the first and second actuators 518 and 528 soas to pivot the first and second arms 512 and 522 away from the batterypack 50 a or 50 d in the released position. As shown in the figures,forward movement the slider button 532 to its default positiondisengages the main body 534 from the first actuator 518 and causesdownward movement of the second actuator 528, thus allowing the firstand second arms 512 and 522 to engage pockets 64 or 74 of battery packs50 a or 50 d in the latched position. A spring member (not shown) may beprovided to bias one or both of first and second arms 512 and 522 awayfrom the battery receptacle 114. The spring member may be provided tobias the sliding actuator 530 in the forward direction.

A width of the slot 536 may be greater than a thickness of the firstactuator 518. This provides some slack for the first interface element510 to traverse relative to the sliding actuator 530. Specifically, inan embodiment, in the released position as shown in the figures, themain body 534 engages the first actuator 518 to cause rotation of thefirst arm 512 away from the battery pack 50 c. However, in the latchedposition, the first actuator 518 is allowed to move downward to engagepocket 74 when receiving the short battery pack 50 c as shown in FIG.125, or to rest on top of the battery pack when receiving the longbattery pack 50 d as shown in FIG. 129.

FIGS. 131-142 illustrates various views of another example embodiment ofa power tool battery receptacle 114 provided with another exampleembodiment of a multi-latch mechanism 600 having two interfaces actuatedby a vertically moveable actuator 630, according to a sixth embodimentof the invention. The figures illustrate the multi-latch mechanism 600including the vertically moveable actuator 630.

As shown in these figures, the multi-latch mechanism 600 includes afirst interface element 610 for engagement with the short battery pack50 c and a second interface element 620 for engagement with the longbattery pack 50 d.

The first interface element 610 includes a first arm 612 pivotablycoupled to a first actuator 618 via a first pivot member 614 supportedby the battery receptacle 114. The first interface element 610 furtherincludes a first latch member 616 projecting downwardly fromapproximately an end of the first arm 612. Similarly, the secondinterface element 620 includes a second arm 622 pivotably coupled to asecond actuator 628 via a second pivot member 624 supported by thebattery receptacle 114. The second interface element 620 furtherincludes a second latch member 626 projecting downwardly fromapproximately an end of the second arm 622.

The vertically moveable actuator 630 includes a main planar bodyoriented along a plane that is perpendicular to the top surface of thebattery pack 50 c and extends through an opening 640 of the batteryreceptacle 114. In an embodiment, the opening 640 is sized to allowvertical movement of the actuator 630. In an embodiment, the actuator630 includes an elongate opening 632 that extends laterally (i.e., alongan axis perpendicular to the receiving axis of the battery pack) and ispositioned to receive end of the first actuator 618 of the firstinterface element 610, and a lower end 634 positioned below the elongateopening 632 that is positioned to be coupled to the second actuator 628of the second interface element 620. In an embodiment, the actuator 630is moveable from a default upper position, which is the latchedposition, to a lower position, which is the released position, whenpressed by the user.

In the latched position, the actuator 630 allows the first and secondarms 612 and 622 of the first and second interfaces 610 and 620 toengage pockets of respective battery packs 50 d or 50 c, as shown in thefigures. In this position, the elongate opening 632 is positioned toprovide leeway for the end of the first actuator 618 to move. Movementof the first interface element 610 is therefore not fully fixed to theactuator 630 in the latched position. This allows the first arm 612 ofthe first interface element 640 to freely move downwardly intoengagement with pocket 74 when receiving short battery pack 50 c, or torest on top of the pack housing when receiving long battery pack 50 d.Further, in the latched position, the lower end 634 of the actuator 630is positioned to force the second arm 622 of the second interfaceelement 620 to pivot downwardly into engagement with pocket 64 of longbattery pack 50 d.

In the released position, the actuator 630 forces the first and secondactuators 618 and 628 of the first and second interfaces 610 and 620 topivot the first and second arms 612 and 622 away from the battery pack50 a or 50 d, as shown in the figures. In this position, in anembodiment, end of the first actuator 618 within the elongate opening632 is pressed downwardly, causing the first arm 612 to pivot upwardlyaway from the battery pack 50 a or 50 d. The first interface element 610is therefore fixed to the actuator 630 in the released position.Similarly, lower end 634 is positioned to force the second arm 622 ofthe second interface element 620 to pivot away from battery pack 50 a or50 d.

A spring member (not shown) may be provided to bias one or both of firstand second arms 612 and 622 away from the battery receptacle 114. Thespring member may be provided to bias the actuator 630 in the upwarddirection.

FIGS. 143-150 illustrate various views of another example embodiment ofa power tool battery receptacle 114 provided with another exampleembodiment of a multi-latch mechanism 700 including a side pivotingfirst interface element 710 and a top pivoting second interface element720, according to a seventh embodiment of the invention.

The first interface element 710 is provided for engagement with abattery pack 50 c including sideways-translating latches 80 oriented ontwo sides of the block terminal 84 below guide rails 86 and near frontends of grooves 88. The latches 80 are spring-loaded and are coupled tothe actuators 82 disposed on the front side of the battery pack 50 cthat, when pressed, cause the translating latches 80 to move inside thehousing of the battery pack 50 c in a direction perpendicular to thereceiving axis of the battery pack 50 c. The battery pack 50 c isillustrated as a short battery pack in this embodiment by way ofexample, though it should be understood that battery pack 50 c may be ofany size and may include any latch location.

The first interface element 710 includes a first arm 712 pivotablycoupled to a pivot member 714 supported by the battery receptacle 114.In an embodiment, the first arm 712 actuates a pair of legs 716 thatextend laterally from an underside of first arm 712 and are pivotablearound a pair of side pivot members 715. Two side members 719 extendfrom the side pivot members 715 opposite the legs 716 around the guiderails 86 and include first latch members 718 formed inwardly andreceivable within the grooves 88 of the battery pack 50 c.

The second interface element 720 includes a second arm 722 extendingfrom an actuator 724 to the pivot member 714 opposite the first arm 712.The second interface element 720 further includes a second latch member726 projecting downwardly from approximately a middle portion of thesecond arm 722.

In the latching position, the second arm 722 of the second interfaceelement 720 moves downwardly with the actuator 724. When interactingwith the long battery pack 50 d, this allows the second latch member 726to move downwardly and catch the pocket 64 to lock in the battery pack50 d. Further, the first arm 712 of the first interface element 710 ismoved upwardly opposite the direction of movement of the actuator 724.Thus, when interacting with the short battery pack 50 c, in the upwardposition of the first arm 712, the side members 719 pivot in thedirection of the terminal block 84 and meet the guide rails 86, and thefirst latch members 718 locate within the grooves 88. Thesideways-translating latches 80 of the battery pack 50 c catch the firstlatch members 718.

In the releasing position, with upward actuation of the actuator 724,the second arm 722 of the second interface element 720 moves up and thefirst arm 712 of the first interface element 710 pivots down. The firstarm 712 forces pivoting movement of the side members 719 away from thebattery pack 50 d or 50 c. In this manner, actuation of the actuator 724thus allows removal of either of the battery pack 50 d or 50 c from thebattery receptacle 114.

FIGS. 151-163 illustrate another example embodiment of a powertool-battery pack system, in accordance with the present invention. Inthis example embodiment, the power tool battery receptacle 114 isprovided with another example embodiment of a multi-latch mechanism 800including a side-sliding first interface element 810 and a top pivotingsecond interface element 820.

The side-sliding first interface element 810 is provided for engagementwith the battery pack 50 c including sideways-translating latches 80, asdescribed above. Similar to the first interface element 710 of theaforementioned example embodiment, the first interface element 810includes a first arm 812 pivotably coupled to a pivot member 814supported by the battery receptacle 114. In contrast to first interfaceelement 710 of the aforementioned example embodiment provided withpivoting arms, as described above, the first interface element 810includes a pair of sliding plates 815 that slide in the sidewaysdirection generally perpendicular to the receiving axis of the batterypack 50 c. Each plate 815 is oriented generally perpendicular to the topsurface of the terminal block 84 of the battery pack 50 e. Each plate815 includes a side arm 817 that extends downwardly along the respectiveguide rail 86 and a first latch member 818 projecting inwardly from thelower end of the side arm 817 and is receivable within the groove 88.

Each plate 815 includes a recessed region 832 having a smaller thicknessthan the rest of the plate 815. The recessed regions 832 of the twoplates 815 overlap one another. Each plate 815 further includes anelongated slot 816 formed at an angle (e.g., 5 to 10 degrees) withrespect to the vertical axis. The elongated slots 816 are disposed nearinner edges 830 of the plates 815 within the recessed region 832. Whenthe recessed regions 832 overlap one another, the two elongated slots816 overlap one another at an angle (e.g., 10 to 20 degrees) so as toprovide an opening therethrough. A pin 813 extending from the first arm812 of the first interface element 810 is received through the openingformed by the two elongated slots 816. When the pin 813 is located in anupper position, as shown in FIGS. 17A and 17D, the two plates 815 movelaterally towards one another. As the pin 814 moves downwardly towards alower position, as shown in FIGS. 17B and 17E, the pin 814 slides withinthe elongated slots 816 and moves the two plates 815 laterally away fromone another.

Similar to the second interface element 720 of the aforementionedexample embodiment, the second interface element 820 includes a secondarm 822 extending from an actuator 824 to the pivot member 814 oppositethe first arm 812. The second interface element 820 further includes asecond latch member 826 projecting downwardly from approximately amiddle portion of the second arm 822.

In the latching position, the second arm 822 of the second interfaceelement 820 moves downwardly with the actuator 824. When interactingwith the long battery pack 50 d, this allows the second latch member 826to move downwardly and catch the pocket 64 to lock in the battery pack50 d. Further, the pin 813 of the first interface element 810 is movedupwardly, opposite the direction of movement of the actuator 824. Thus,when interacting with the short battery pack 50 c, in the upwardposition of the pin 813, the sliding plates 815 moves laterally in thedirection of the terminal block 84 until the side arms 817 meet theguide rails 86, and the first latch members 818 locate within thegrooves 88. The sideways-translating latches 80 of the battery pack 50 ecatch the first latch members 818.

In the releasing position, with upward actuation of the actuator 824,the pin 813 of the second interface element 820 moves up, causing thesliding plates 815 to move laterally away from the terminal block 84 ofthe battery pack 50 e and disengage the first latch members 818 from theguide rails of the battery pack. In this manner, actuation of theactuator 724 thus allows removal of either the battery pack 50 d or 50 cfrom the battery receptacle 114.

The foregoing description of the embodiments has been provided forpurposes of illustration and description. It is not intended to beexhaustive or to limit the disclosure. Individual elements or featuresof a particular embodiment are generally not limited to that particularembodiment, but, where applicable, are interchangeable and can be usedin a selected embodiment, even if not specifically shown or described.The same may also be varied in many ways. Such variations are not to beregarded as a departure from the disclosure, and all such modificationsare intended to be included within the scope of the disclosure.

Example embodiments are provided so that this disclosure will bethorough and will fully convey the scope to those who are skilled in theart. Numerous specific details are set forth such as examples ofspecific components, devices, and methods, to provide a thoroughunderstanding of embodiments of the present disclosure. It will beapparent to those skilled in the art that specific details need not beemployed, that example embodiments may be embodied in many differentforms and that neither should be construed to limit the scope of thedisclosure. In some example embodiments, well-known processes,well-known device structures, and well-known technologies are notdescribed in detail.

The terminology used herein is for the purpose of describing particularexample embodiments only and is not intended to be limiting. As usedherein, the singular forms “a,” “an,” and “the” may be intended toinclude the plural forms as well, unless the context clearly indicatesotherwise. The terms “comprises,” “comprising,” “including,” and“having,” are inclusive and therefore specify the presence of statedfeatures, integers, steps, operations, elements, and/or components, butdo not preclude the presence or addition of one or more other features,integers, steps, operations, elements, components, and/or groupsthereof. The method steps, processes, and operations described hereinare not to be construed as necessarily requiring their performance inthe particular order discussed or illustrated, unless specificallyidentified as an order of performance. It is also to be understood thatadditional or alternative steps may be employed.

1. A power tool comprising: a housing; and a battery receptacle formedin the housing or coupled to the housing, the battery receptacle capableof receiving a first battery pack having a first latching location or asecond battery pack having a second latching location, the batteryreceptacle comprising a multi-latch mechanism configured to engage thelatching location of first battery pack when receiving the first batterypack and engage the latching location of the second battery pack whenreceiving the second battery pack.
 2. The power tool of claim 1, whereinthe battery receptacle comprises a power terminal block and at least oneguide rail for guiding the battery packs along a receiving axis so as tomake an electrical connection with the power terminal block.
 3. Thepower tool of claim 2, wherein the first latching location is closer tothe power terminal block than is the second latching location.
 4. Thepower tool of claim 1, wherein the multi-latch mechanism includes afirst latch hook pivotable around a first pivot member and a secondlatch hook pivotable around a second pivot member.
 5. The power tool ofclaim 1, wherein the first battery pack comprises a pocket at the firstlatching location.
 6. The power tool of claim 1, wherein the secondbattery pack comprises a translating latch at the second latchinglocation moveable via an actuator in a direction perpendicular to areceiving axis of the second battery pack.
 7. A power tool comprising: ahousing; and a battery receptacle formed in the housing or coupled tothe housing, the battery receptacle comprising a multi-latch mechanismcomprising a first latch interface for engaging a first battery packwhen the first battery pack is received in the battery receptacle and asecond latch interface disposed at a distance from the first latchinterface for engaging a second battery pack when the second batterypack is received in the battery receptacle.
 8. The power tool of claim7, wherein the first latch interface comprises a first arm pivotablearound a first pivot member and having a first latch hook for engagingthe first battery pack, and the second latch interface comprises asecond arm pivotable around a second pivot member and having a secondlatch hook for engaging the second battery pack.
 9. The power tool ofclaim 8, wherein the multi-latch mechanism further comprises an actuatorconfigured to move both the first latch interface and the second latchinterface from a latched position to a released position.
 10. The powertool of claim 9, wherein the second latch interface is integrally formedwith the actuator.
 11. The power tool of claim 9, wherein a first end ofthe first arm is coupled to the first pivot member and a second end ofthe first arm is coupled to the actuator.
 12. The power tool of claim11, wherein the second end of the first arm is unfixedly coupled to theactuator.
 13. The power tool of claim 8, wherein the first latchinterface is coupled to a first actuator and the second latch interfaceis coupled to a second actuator independent from the first actuator. 14.The power tool of claim 7, wherein the first latch interface comprises afirst lateral recess arranged to engage a first translating latch of thefirst battery pack and the second latch interface comprises a secondlateral recess distanced from the first lateral recess arranged toengage a second translating latch of the second battery pack.
 15. Thepower tool of claim 7, wherein the first latch interface comprises apivoting arm for pivoting engagement with the first battery pack and thesecond latch interface comprises a lateral recess for engagement with atranslating latch of the second battery pack.
 16. The power tool ofclaim 7, wherein the first latch interface comprises a first pivotinglatch hook and the second latch hook comprises a second pivoting latchhook, wherein the multi-latch mechanism further comprises a slidingactuator configured to move along an axis parallel to a receiving axisof the first and second battery packs.
 17. The power tool of claim 16,wherein the sliding actuator includes a slot that engages the firstlatch interface and an end that engages the second latch interface. 18.The power tool of claim 17, wherein the slot is sized to allow relativemovement of the second latch interface relative to the sliding actuator.19. The power tool of claim 7, wherein the first latch interfacecomprises a first pivoting latch hook and the second latch hookcomprises a second pivoting latch hook, wherein the multi-latchmechanism further comprises a push actuator configured to move along anaxis perpendicular to a receiving axis of the first and second batterypacks.
 20. The power tool of claim 19, wherein the sliding actuatorincludes a slot that engages the first latch interface and an end thatengages the second latch interface.
 21. The power tool of claim 20,wherein the slot is sized to allow relative movement of the second latchinterface relative to the sliding actuator.
 22. The power tool of claim7, wherein the first latch interface comprises a pair of pivoting armsarranged to engage side grooves of the first battery pack.
 23. The powertool of claim 7, wherein the first latch interface comprises a pair ofsliding side plates arranged to engage side grooves of the first batterypack.